Manufacture of wire strands



Y 10 Shee ts-Sheet l INVENTOR qnvnv Muss HHRRIS flr'roelvcvs s. M. HARRIS File d March 29, 1958 MANUFACTURE OF WIRE STR ANDS 12 LEE May 2, 1939.

G. M. HARRIS 2,156,652

MANUFACTURE OF WIRE. STRANDS Filed March 29, 1938 l0 Sheets-Sheet 2 INVE'NTOR qnvm Mues'Hnems M. HARRIS Q MANUFACTURE OF WIRE STRANDS Filed March 29, 1938 10 Sheets-Sheet 3 y 2, 1939- G. M. HARRIS 2,156,652

MANUFACTURE OF WIRE STRANDS Filed March 29; 1938 10 SheGtS-Shet 4' 59 49 56 I Hi 5 ||u [Ill INVENTOR -AVIN Mae: Hamel;

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ATTORNEYS y 41M. HARRIS 5 2,156,552

MANUFACTURED? WIRFSTRANDS;

. Filed Match 29,1938 l0'Sheets-Sheet 7 I INVENTOR qn vnv Mun: flnknls Maya, 1939- GLM. HARRIS 2,156,652

MANUFACTURE o? WIRE STRANDS Filed March 29, 1938 10 Sheets-Sheet 8 v INV ENTOR qnw v Mae: Ila mus M,m fiM i 1939: G. M. HARRIS MANUFACTURE OF WIRE STRANDS Filed March 29, 1938 May 2, 1939. HARRIS 2,156,652

' MANUFACTURE OF WIRE STRANDS F iled March 29, 1938 10 Sheets-Sheet 1o jFigl22.

HTra/QN Y5 Patented May 2, 1939 ruro STATES PATENT OFFICE" MANUFACTURE OF WIRE STRANDS Gavin More Harris, London, England, assignor to Callenders Cable and Construction Company Limited, London, England, a British company- Application March 29, 1938, Serial No. 198,666 In Great Britain March 16, 1936 13 Claims. (01. semis) completely than is the case with circular wires and thus leave between them less volume of unoccupied space. Such strands are referred to hereinafter as compacted wire strands.

This application is a continuation-in-part of 15 my copending application, Serial No. 131,255,

filed March 16, 1937, for the Manufacture-of wire strands.

In particular the invention is concerned with the manufacture of compacted wire strands consisting of one or more layers of wires. The strand so formed may be hollow or closed, may be circular or non-circular. It may be complete in itself or may form the inner part of a strand built up around it. The number of wires included in the strand is variable and dependent upon the requirements of each case. In the case of closed strands of circular shape consisting of a single layer of wires, it is preferred to use four wires, but the method of manufacture is applicable tonuinbers of wires from three upwards.

The invention is concerned with the method of producing a deformation of the wires from their original circular form to a shape which approximates to a sector or a truncated sector. The

wires aredeform'ed and brought into the desired degree of closeness of fit against their neighbours by a process which forms part of the procedure gone through in the assembly of the wires in the strand.

In the improved method of manufacture of compacted wire strand, circular wires are drawn separately between shaping members, being thereby deformed, the deformed wires are then assembled, laid up helically together and drawn through a die, and are further deformed and simultaneously consolidated in a strand.

The method of deformation of the wires is by drawing with or without the assistance of rolling. The following definitions are assumed:

(1) Drawing is effected by applying the tractive force required to cause the strand or wire to pass through a fixed die or a roll die, 'wholly to the leading end of the strand or wire.

(1) Rolling is effected by transmitting the necessary tractive force to the wire or strand to "cause it to pass therethrough by means of the rolls themselves.

In the process three operations are performed on the wires. In the first of these the separate wires are subjected to radial compression. In 5 the performance of the second operation, the

wires are assembled and circumferential compression is exerted on each wire by its neighbours. In the performance of the third operation, the assembled wires are compressed so that the final 1o shape and dimensions are given to the strand.

These three operations may be performed by;

three separate elements of a machine but in some cases two of the operations may be performed by the same or closely associated ma- 1! chine elements. Two of the operations, in some instances may follow each other in the same part of the machine, and may even merge into each other.

The shaping of the wires is performed while 20 they are approaching each other to be assembled together in a single layer with the usual helical twist. The first operation of the shaping process is performed while the wires are still separated from each other. According to the invention it 25 may be performed by a ring of separate dies, (each of which may be a group of rolls) one die for each wire, or by means of a single mandrel and a single die, the die having a tapering aperture, circular in section and surrounding the mandrel with a small clearance-to form a converging annular throat. Alternatively, the shaping members may be a tapering mandrel, provided with shaping grooves, and a tapering die, and each wire will be deformed by contact with a groove and the die.

The second operation is performed by a die with a tapering mouth into and through which the deformed wires are drawn and within which they are assembled together in a layer. The final so dimensions of this die are such that the wires coming from the first operation must undergo further change of shape in order that the assembly of wires may pass through.

The die for the second operation may be as formed as acontinuation of the die which has performed the first operation or it may be a separate die spaced axially away from the first die.

ally into fixed parts or into rolls which are free 50 It may be a solid die or may be split radito turn. It may rotate with the bobbin carriage of the stranding machine or may be stationary.

The third operation is performed by means which is, for convenience, hereinafter referred to as the final die. It may consist of a single die 55 rolls. Some or all of' the rolls may be driven to exert a rolling action on the strand. In some cases of the manufacture of a circular-compacted strand, the die for the third operation may form part of, or be merged into, the die for the second operation. When manufacturing a non-circular compacted strand by the improved method, the

required strand shape'will be given by the third operation, which will usually be effected by ,a structurally separate die.

The invention is also concerned with the manufacture of non-circular, compacted wire strand of pre-spiralled form. That is to say, if the compacted strand is to form one of several which are subsequently to be laid up together it may be desired to pre-spiral the strand (that is, to give it a form which is twisted about an axis within itself) as the wires are being assembled. This twisted form has the lay of the final group of strands and may be produced by the rotation of the final die at the appropriate rate strand through it. The pre-spiralling lay is generally longer than the lay of the wires in the strand.

The invention is also concerned with the production of a hollow single-layer compacted wirestrand of circular or non-circular cross-sectional shape, in which the interior and the crevices on the inside of the layer of wires are completely filled with a rubber compound, bituminous compound or other mouldable, flexible and coherent material. By the improved method such a compacted strand is produced by compacting the component wires about a core of the filling mate-' rial. The core is introduced within the group of wires of which the strand is to be fo' ed, and is passed simultaneously with them through the apparatus in which the wires are subjected to the above-mentioned deforming operations. During the second'and third operations, but more particularly-during the third operation, the core is radially compressed by the surrounding wires, thereby being caused to fill completely the central space within the strand and to be forced into the crevices on the inner surface of the surrounding layer of wires. The original cross-sectional size of the core is made great enough, in comparison with the internal dimensions of the compacted wire strand, to ensure that the internal,

cavity and the crevices of the strand are completely filled in the finished product.

According to a further feature of the invention, instead of being formed wholly of mouldable, flexible and coherent filling material, the

core may have embedded therein a wire, or group of wires, hereinafter referred to, for convenience,

as an inner wire. In this case the size of the inner wire will be such that in the finished strand there will remain between the inner wire and the inner surface of the surrounding layer of wires a body of the filling material which completely separates the inner wire from the outer wires ed wire strand may subsequently be provided in any known manner with an insulating covering of a similar rubber compound, for instance, applied longitudinally, which will fill the crevices on the outside of the strand. The rubber compound forming the core, and the covering if applied, may be subsequently vulcanised in one operation.

1 Another feature of the improved method concerns the manufacture of compacted wire strands of two or more layers in which the compacting of the wires is effected layer by layer, that is in single layers, and the number and diameter of the wires of each layer are so chosen that these wires, if assembled in a layer of the desired form but without deformation of the wires, would not fit upon the next inner layer, that is to say they would enclose a space larger than that occupied by the part of the strand which is to lie within them.

I In following the usual procedure of building up a strand from a number of cireular wires all of the same initial size, the numbers taken for the layers would be different in the present case from those usually adopted. For instance, starting with a single wire as the centre the next layer would consist of eight wires, the next outer one would consist of sixteen wires and the next outer one of twenty-four wires. The total number of wires included by any layer and those within it will be seen to be as follows: 1, 9,

. and 49. As another example, starting with four wires, the next layer would consist of twelve, the next of 20 and the next of 28. The numbers enclosed by any layer would then be as follows: 4, 16, 36 and 64. It will be noticed that in each case thenumber of wires enclosed by any layer is a square number. This method, following the usual practice of using wires of the same size throughout, will, generally, be found most convenient, but it is not essential to the invention that it should be adopted. By asimultaneous adjustment of the diameter of wires and number of wires per layer, the indicated conditions can be obtained. By taking wires of the same size in each layer and in numbers as indicated above the minimum deformationof each wire would usually be obtained. Similarly the taking of the increased volume of round wires per layer in ac.- cordance with this feature of the invention results in the production of a compacted strand with less deformation than would be required if the normal number. and sizes of wires were employed. Flu'ther, since the method gives control of the closeness of fit of each layer on its next adjacent inner layer, the deformation or compression of such layers when assembling outer layers on them can be avoided.

In the compacting of the strand each wire, other than the wires of a single layer solid strand, changes from the circular shape to a shape in which the cross-section approximates to a figure bounded by two radial lines and two circular arcs, that is, a truncated sector. This is done, in

the manner previously, referred, by a drawing process, with or without the assistance of rolling, involving three operations which may be effected in two stages by combining, in the manner already described, the flrst and second or second and third operations into one stage. At the end of the operations the deformation of the wires of the layer being operated upon is substantially complete at the time of first engagement between the adjacent surfaces of the layer and the inner part of the strand around which it is formed.

The improved method of manufacture is more particularly described hereinafter and illustrated, by way of example, in the accompanying drawings wherein:

Figure 1 is a view of part of one form of stranding machine for carrying out the process;

Figure 1A is a view of the remaining part of the machine represented in Figure 1;

Figure 2 is a view of part of another'form of stranding machine for carrying out the process;

Figure 2A is a view of the remaining part of the machine represented in Figure 2;

Figure 3 is a view,- in' part section, of a portion of the machine shown in Figures 2 and 2A on a larger scale;

Figure 4 is a similar view of a modified form of the arrangement shown in Figure 3;

Figure 5 is an end view of a modified form of a portion of the machine shown in Figures 2 and 2A; V

Figure 6 is a sectional view of the arrangement shown in Figure 3 on the line VIVI;

Figure 7 represents to a larger scale a portion of the machine shown in Figures 1 and 1A;

Figure 8 represents a modified form of the arrangement shown in Figure 7; I 4,

Figure 9 is a sectional view taken on the line IX-IX in Figure 8;

Figure 10 is another modification of the arrangement shown in Figure I; I

Figures 11 to 22 are diagrammatic representations illustrating the various stages of the process of forming various constructions of com.- pacted wire strand in accordance with the invention; and

Figure 23 is a view similar to that of Figure 6 of a modified form of the arrangement shown in Figure 6.

The machine illustrated in Figures 1 and 1A comprises a hollow shaft I rotatably mounted at its ends in bearings 2 and 3 and having keyed thereto a bobbin carriage d which is additionally supported at about its centre by freely rotatable rollers 5. In the bobbin carriage i are mounted a set of bobbins 6, each one of which supplies one of the wires 1 of which a compact wire strand is to be constructed, the number of bobbins corresponding with the number of wires in the strand. The bobbin carriage is rotated by means of gears,8 located at the back of the machine behind the rearmost bearing 2. Each bobbin 6 is rotatably supported, with its axis disposed transversely to the axis of the hollow shaft l, in a frame 9 which is freely mounted in the bobbin carriage 5, and is provided with a crank lever l0 projecting vertically downwards at the rear of the carriage. The ends of all the crank levers iii are connected to a weighted ring' it which, as the bobbin carriage d rotates, maintains each crank lever id in the vertical, dependent position, thereby maintaining each bobbin I6 projecting forward from a flange I? formed on the end of the shaft l.- The wires l passing from the final guide pulleys 13 pass through the frame of the forward bearing 3 and converge on the axis of the machine in the tapering mouth of the die M. A tapered mandrel is, mounted ing forward from the centre of the flange I1, is

located with its reduced end inserted within the mouth of the die H. The mandrel I8 is carried by a rod 39 which slides within the tube l3 and the mandrel I8 is maintained in its forward position by means of a compression spring 36 which surrounds the rod 39, hearin at one end upon the end of the tube It and at the other upon a collar 31 formed behind the mandrel on the rod 39. The forward end of the tapered mandrel is preferably ground to a spherical shape. There is thus formed by the die H and the forward end of the mandrel It a converging annular throat through which the wires I pass and are operated upon in a manner hereinafter described. The pressure of the mandrel I8 upon the wires is regulated by screwing the tube l9 into or out of the flange II. The effect of the spring 36 is to permit the mandrel It to float so as to equalise, and to obtain a fine adjustment of, the pressure applied upon the wires. The wires 1 are stranded together in the die H, and the strand 20 thus formed is drawn through a final die 2| whereby it is further operated upon. After leaving the final die 2! the finished strand is wound around a capstan 22 by means of which the longitudinal movement of the wire through the machine has 25 which is mounted within a bearing 26 and is adapted to be rotated about the axis of the machine by means of a chain-drive 21 if desired.

Behind the machine is located a stand 28 upon which may be mounted a bobbin for supplying a core of filling material during the production of a filled hollow compact wire strand. In this case the core passes through the hollow shaft I, through a central bore 38 formed for this purpose in the mandrel l8 and in its supporting rod 39, and is enclosed within the wire strand 20 as the latter is formed within the die Id.

In, Figures 8 and 9 is shown another arrangement of dies which may be used in place of the arrangement already described with reference to Figure 7. In this modification there are disposed on the flange ll in a circle about the axis of the machine a number of pairs 3! of rolls. The die It is provided as before, mounted in a die-holder i5 between two rods 56, but the mandrel described in connection with the previous arrangement is omitted. In this construction the function previously performed by the mandrel in conjunction with the die M is performed by the group of pairs 3! of rolls before the wires converge at the die M. i

In Figure 10 is shown a further modification of this arrangement which is a combination of the previously described arrangements. In this construction there is provided a ring of pairs 3| of rolls mounted on the flange ii, a dield mounted in a die-holder I5 between 'two rods l5, and a tapering mandrel i6 located with its forward end within the mouth of the die M. The function which in the construction shown in Figure 7 is performed in the converging annular throat between the mandrel i8 and die 14, and which, in the construction shown in Figures 8 and 9, is performed by the pairs 3| of rolls, is in this construction performed in part by the pairs of rolls and them; quadrant B showing the efiect of radial compression on the separate wires, quadrant 0 their assembly into the strand and their partial compacting, and quadrant D the final consolidatiOn.

Figure l1 represents the formation of the first of four principal types of products. This is a 'closed circular strand in which each of four wires approximates to a sector in shape. In the first operation the round wires 1 are each passed through a pair of rolls 3| (Figures 8.

and 9) which are shown as rotating in a plane radial to the axis of the machine. Inthe surface of one roll is a deep groove, in the other a shallow groove or no groove at all. The inner part of each wire is'forced to take up a V-shape, and,

at the same time, the radius of curvature of the outer part of the wire is increased. In order to obtain this shaping of the wires, the groove 32 formed on the inner roll will be of V-shape, or

of a parabola or other shape, having its sides approximately inclined to each other at an angle near to that which the sides of the wire will have when finally assembled in the strand. Thus in this case, since the strand consists of four wires, the sides of the wire will be at 90 and the sides of the groove 32 may enclose an angle equal to this or somewhat greater or smaller. It is convenient to make a strand of this type of four wires, but the method is applicable to numbers from three upwards. After passing between a pair of rolls 3| each wire has been deformed as indicated in quadrant B. The wires now converge to the mouth of the die H, in which they are stranded together, and compressed, so as to bring them to the sector form as shown in quadrant C. In this second operation or partial compacting, the sides of each wire are pressed by engagement with the adjacent wires in such a way as to cause the metal' tomove towards the corners of the sector and make-these corners sharper. The curvature of the outside of each wire is also constrained to approach more nearly that of the final form. The third and final operation is effected in the final die. In this final operation the strand is given its finished compacted form as represented in quadrant D, in which the shape of each wire approximates to a sector, and the amount of unoccupied space between the wires of the strand is a minimum. v

Figure 12 illustrates the formation of the second principal type which is a hollow circular strand in which the final shape of each wire is the form of a truncated sector. The strand represented in this figure is constructed of eight wires I, originally of circular shape, and which, if assembled undeformed, would have the form indicated in quadrant A. In the first operation each wire is radially compressed by passage through the converging annular throat formed passagethroughthe die l4 .the wiresare assembled and partially compacted to the shape shown in quadrant C. The final compacting to' the form shown in quadrant D is efi'ec'te'd by a die in manner similar to that of the previous case.

In such a strand which is intended to be selfsupporting the central space 33 constitutes a comparatively small proportion of the total area of cross-section, say, not more than 15%. If such a hollow strand is to be supported by some outer layer of wires or other wrapping then it is possible to make the cavity a larger proportion of the total area.

Figure 13 illustrates the production of a third principal form of strand which is closed, and is of non-circular section. The strand represented in this figure is of eight wires I, originally of circular shape as shown in quadrant A. The wires are first deformed by radial compression to the form shown in quadrant B in a manner as described with reference to Figure 11. They are then assembled and partially compacted'to 'form a circular strand as represented in quadrant C represented in quadrant D.

In Figure 14 is illustrated the fourth principal type ofcompacted wire strand which is hollow and of non-circular section. It is produced in a manner similar to that employed in the production of the hollow circular strand above described, excepting that the final die completes the consolidation of the strand to a non-circular shape.

.Either of the non-circular strands described above may be pre-spiralled during the third and final operation of the process. This is effected by rotating the final die about the axis of the machine by means of the chain drive 21, (Figure 1A). The speed of rotation of the final die is so regulated with reference to the forward movement of the strand that the finished strand is pre-spiralled with a pre-determined pitch, which itselfdepends upon the requirements of subsequent cable-forming operations.

In the production of the strands represented in Figures 12 and 14, the first and second stages of the deformation of the wires may be carried out by means of a modified arrangement of dies, such as is shown in Figure 8. That is to say, the first deformation of the wires may be effected by passing each one through one of a ring of dies, such, for instance, as the groups of rolls 3 I. In this case, the use of a mandrel l8 (Figure '7) is not essential and the second operation only of the process is carried out in the die M, to which the wires converge, and in which they'are assembled. Alternatively, the combined arrangement of dies shown in Figure 10 may be used.

The interior of a hollow, non-circular compacted'wire strand may be completely filled with.

a core of mouldable, flexible and coherent material. In the preferred method this material consists of unvulcanised or partially vulcanised rubber compound which is sufiiciently plastic to enter readily the crevices between wires on the inside of the layer. It may be introduced from the second stage of the process. During the,

second and third operations, but more particularly during the third operation, the core is radially compressed by the surrounding wires, thereby being caused to fill completely the central space within the strand and to be forced into the crevices on the inner surface of the surrounding layer of wires (quadrant D Figure 15). The original cross-sectional size of thecore is made great enough, in comparison with the internal dimensions of the compacted wire strand, to ensure that the internal cavity and the previces of the strand are completely filled in the finished product. A hollow circular compacted wire strand such as is indicated in Figure 12 may be filled with such material in a similar manner, as is illustrated in Figure 16.

As represented in Figures 17 and 18 the core of filling 'material may have embedded therein a wire, or a group of wires, which will, in the finished strand, be completely separated from the outer wires by the filling material. Figure 17 illustrates the production of a circular strand having a core 33 of the filling material in. which one wire 3% is embedded. Figure 18 illustrates sectional area as each of the outer wires.

a non-circular strand having a core of filling material in which two'wires 3b are embedded. In both these constructions the number of wires in the compacted layer is so chosen as to permit such reduction in.their radial thickness being effected in the compacting of the layer to its final diameter that in the finished strand there remains between the embedded wires and the inner surface of thesurrounding wires a body of the filling material, which completely separates the inner wire from the outer wires and fills the otherwise unoccupied space enclosed by the outer wires.

The strand represented in Figure 17 consists of an outer layer, formedirom six originally circular wires i, and the inner wire it. The latter is circular and of substantially the same cross- The strand represented in Figure 18,consists of an outer layer, formed from eight originally circular wires 7 and the two inner wires 35. The latter are each circular and of substantially the same cross-sectional area as each of the outer wires. In the construction of both forms the first and second stages of the deformation of the wires are carried out either by the arrangement 01 dies in Figure 7, or by those according to Figure 8, or by means of the apparatus described above with reference to Figure 10. By the latter arrangement the first deformation of the separate wires is enacted in two steps, first by passage through groups of rolls 3|, and secondly by passage between the mandrel I 8 and die M. The radial thickness of the Wires 1 will generally need to be reduced to a greater extent than in the case of the other types of holiow compacted wire strands. The second and third operations are efi'ected in'a manner as already described. In the finished strand the reduced radial thick ness of each of the outer wires allows suilicient clearance for accommodation of the filling material between the inner and outer wires.

- :39 twenty-four bobbins.

ner similar to that described previously for a homogeneous core 30 of filling material.

a The stranding machine represented in Figures 2 and 2A is adapted for the production of a compacted wire strand consisting of a number of layers, in which each layer is compacted independently of that part of the strand which it 61163].

In the particular example illustrated the strand to be formed comprises a single axial wire core 8| about which are laid three concentric layers of wire, d2, 43 and M consisting of 8, l6 and 24 wires respectively. The central wire dl is supplied from a bobbin t5 mounted upon a stand as at.the back of the machine. The successive layers of wire d2, t3 and as are applied by means oi three cages d1, t8 and :89 adapted to rotate about the common machine axis, being built upon hollow shafts 5d, El and 52, each of which is supported in a bearing 53 at the rear and a bearing es at the front of the cage. The drive to each cageis obtained from a lay shaft 55 disposed parallel to the machine axis, a gear wheel 56 located on the shaft at the rear of each cage being maintained in communication with the layshaft lit by means of a train of gears 51. The gear-train drive to the central cage A8 is such that the cage may rotate in direction opposite to that of the first and third cages d? and ea or in the same direction as those cages so that the direction of lay of the wires 53 may be the same or opposite to that of the underlaying and overlaying'wires t2 and M. A capstan 58 mounted in front of the machine, adapted to be driven from the lay-shaft 55, serves to draw the strand through the machine. Each rotating cage carries the appropriate number of bobbins 59 loadedwith wire. ..Thus the cage dl carries eight bobbins, the cage dd sixteen bobbins and the cage mounted on a stationary spindle 66 so as to rotate thereon as the wire is withdrawn. In an alternate arrangement the bobbins may be mounted in cradles, such as the frames 9 of the machine shown in Figures 1 and 1A, adapted to give a back rotation in known manner with respect to the motion of the cages in order to counteract the twisting of the wires as they am drawn from the bobbins. Furthermore, each of the cages d1, 68 and all may be caused to rotate in the same direction by suitably selecting the driving gears 51, in which case the direction of twist of each layer of wires in the strand would be the same, although the pitch. of twisting will usually be different for each layer. After leaving the bobbin each wire passes round a guide in the form of a small freely rotatable pulley 6|. The guide pulleys 6i are arranged radially round the machine axis upon carriers 62 fixed to the hollow shafts 50, 5! and 52. Each wire passes from the guide pulley to a head 63 located in front of each bearing 54, fixed to the end of each of the shafts 50, 5! and 52 and consequently rotating with the corresponding cage.

The first stage of the strand-forming operation is performed in the head 63. In front of each head $3 and close to it is mounted a die 64 which may be fixed or made to rotate. In the arrangement shown in Figures 2 and 2A each die 64 is fixed, being mounted on a pedestal 65. The second stage of the strand-forming operation takes place in the die 64. In front of the supply bobbin 45 for the central wire. is also mounted, on a pedestal 61, a fixed die 66 through which the wire 4| is drawn to ensure that its cross-sectional area Each bobbin 59 is' is reduced to the same extent as that of the individual wires of the superimposed layers during the strand-forming operation. I

The rotating head 88 located in front of the' first cage 41 is shown in greater detail upon a larger scale in Figure 3. It comprises a mandrel 68 and a die 88, referred to hereinafter with reference to this illustration as the first die; the die 84 situated in front ofthe head 83 is referred to as the final die. The mandrel 68 is of approximately conical form, tapering towards its forward end. The first die 88 is mounted in a die carrier I8 provided with radial arms II which are slidably engaged with two or more parallel guide bars 12 attached, together with the mandrel 68, to the cage spindle 50. The tapered end of the mandrel 68 is inserted within the end of the first die aperture, so as to leave between the two surfaces a converging annular throat 13, the size of which is regulated by sliding the die carrier 18 on the rods I2, locking screws I4 being provided to fix the die carrier in the desired position. The radial dimension of the throat I8 is adjusted to be less than the diameter of the wires to be drawn therethrough. 1

Figure 4 represents a modified form of the rotating head 83, in which the first die is divided into two members. The first of these is a die- 1 plate 15 having a central aperture into which the tapered end of the mandrel 88 is inserted to form the converging annular throat 92. The other member comprises a die 16, preferably a two-part member, mounted in a die-carrier 11. Both members are slidably mounted between two parallel screw-threaded guide-bars 18, projections 80 on those members engaging the bars and being clamped thereto in the desired positions relative to one another and the mandrel by means of nuts 19 threaded on the guide bars.

In both arrangements illustrated the mandrel 68 has a central aperture 8| through which passes the central wire 4|, or in subsequent stages the previously stranded core, aboutwhich the new layer of wires is to be placed. The core may, for instance, comprise a single layer compacted wire strand such as described above with reference to Figures 11 to 18. The surface of the mandrel has grooves 62, corresponding to the number of wires to be applied at this stage, which 50 serve to ensure that the wires are held in the correct spacing. The grooves 62 are comparatively deep at the point of entry of the wires, in order to prevent their displacement. The angle of taper of the mandrel 68 is increased at the forward end thereof, as indicated (88) in Figure 5, thereby reducingthe depth of the grooves so as to permit the wires to be engaged in the delayer of eight wires 42 surrounding the single central wire 4|. If the originally round wires were arranged as shown in quadrant A of Figure 19 concentrically about the inner wire 4|, touching one another so as to form a layer of circular section, the enclosed space would be substantially larger than that occupied by the. central core.

This applies also in the case of succeeding layers.

mouth of the first die 69, as represented in section in Figure 6, subsequent movement of the wires through this die effecting the second operation, that is, continuing the compacting and assembling of the deformed wires about the central core so that when they leave this die the wires are assembled about the core in the manner shown in quadrant C of Figure 19. In the arrangement of Figure 4 the initial change, of shape occurs in 'the mouth of the die plate member 15 of the first die, the continued compacting and assembly of the wires being effected in the other part 16 of the first die. Thus is effected the preliminary stage of the compacting operation. The final die 64 .located in front of each rotating head 63 is of slightly conical form and serves to complete the compacting of the appropriate layer of wires The strand issuing from the die 64 is in the form of a compacted wire strand as-represented in quadrant D of Figure 19. As previously mentioned this second die 64 may be stationary as represented in Figures 2 and 2A, or it may be rotatable. It may comprise one or more units each consisting of a known form of stationary or roller die. The internal dimensions of the dies will be determined by the size of the strand at the situation of the individual dies and will naturally increase progressively as the strand is built up.

By the machine above described the strand manufactured comprises a single central wire with three concentric layers applied thereto consisting of 8, l6 and 24 wires respectively.

If a larger strand is required, further layers may be applied by the addition in a known manner of further stranding cages each provided, in

the manner previously described, with the requisite number of bobbins. Further, the single central wire may be replaced by a composite four-wire core of compact form, the layers of the subsequently formed strand consisting of 4, 12, and. 28 wires, 1. e., each layer containing eight more wires than the succeeding layer. The

central compact four-wire core may be supplied from the single bobbin 45 at theback of the machine. Alternatively it may be formed from four round wires in a manner similar to that already described with reference to Figure 11 or to thatemployed in forming the succeeding layers. Thus the single bobbin may be replaced by a stranding unit, similar to the stranding unit I but mounting four bobbins for the supply of four round wires. These four wires, if twisted together without deformation, would produce a strand, a cross-sectional view of which would be as represented by the group of circles 93 shown in broken lines in Figure 22., In order to obtain a compacted four-wire core, the wires are passed, during. stranding, through a head such as the one shown in Figure 3 or in Figure 4, the view in Figure 23 representing their passage through the first-mentioned form. The mandrel 84 may in this case be solid and is formed with four' surface grooves 85 of quadrantal cross section. This "form of the grooves 85 ensures that during the drawing operation in the converging annular throat 86 between the end of the mandrel s4 and the first die 81 the wires will be given'substantially a quadrantal section 83 (Figures 22 and 23). During their subsequent passage through the die 81 and a final die, deformation of the wires is completed to obtain a comcted circular core 94 such as is shown in part in Figure 22. Further compact layers may be applied in the manner described above with reference to the single wire core, the lower-portion of Figure 22 representing the application of the first, as. of such layers. The compact layer as is formed of 12 wires, originally circular and equal in. diameter to the original diameter of each of the four inner. wires, and which if stranded about the compact four-wire core without defortion would occupy a position as represented by the outer arrangement of circles at shown in broken lines.

strand, a strand of some other final form is relayers touching the preceding inner layer by the action of the final die in the manner al--,

ready describedwith reference to the production If, instead of the production of a circular of a single layer compacted wire strand. The.

control of the wires during assembly and of the shape given 'to'the layer by the process of compacting described, permits of the making of layers of different shapes, each layer making contact with the next at smaller or greater regions instead of over the complete surface, the increase in the number of wires in each succeeding layer not being necessarily the same as in the case of the circular strand. For instance, a strand having an oval shape may be produced from a circular inner part, the innermost layer touching this circular part, and each of the outer of the minor axis of the ellipse.

Such an oval shaped compact strand is illustrated in section in Figure 21. It comprises a single central round wire 89, with two superimposed layers of wires, the innermore layer Qt of which is formed from ten round wires which, if-

assembled undeformed about the central wire would occupy the circular position represented in the quadrant E in Figure 21. The wires of this layer are, however, subjected to the deforming process described above in connection with the circular strand so as to be successively deformed in the manner represented in quadrants F, G and H of Figure 20. The oval shape, represented in quadrant H,- and in the illustration of the complete strand in Figure 21, is immrted by the final die during the last compacting stage, the aperture of this die being shaped in accordance with the required cross-sectional shape.

Thus there is formed a self-supportingcompacted oval layer of wires which touches the circular interior member 89 only about the minor axis'of the ellipse. Similarly another compacted layer 9| of twenty wires may be formed about the first layer 90, touching that layer only aboutthe minor axis.

The substantial independence of the structure of each layer, of a multi-layer compacted wire strand produced in accordance with the invention, on the form and nature of the layer or core which it encloses, permits the use. of various ma- 1 terials, either metallic or otherwise, for the central part of the strand. Similarly the whole strand can be produced by building up a number, say three, of compacted layers without a central core.

In a conductor formed as a hollow compacted wire strand with filled interior in accordance I with this invention, there. will exist no spaces into which moisture can be drawn in the event ,oi the cable, incorporating such a conductor,

breathing during heating and cooling cycles. Furthermore, there can be no movement of moisture along the conductor from a localized penetration of the outer covering. A cable incorporating such a moisture-prmf conductor is conseouently not subject to deterioration by the penetration of moisture along the conductor. By the carrying out of the process of forming the compacted wire strand in stages, a more compact strand can be made for a given reduction of cross-sectional area than would be the case if single stage working .only were employed. Alternatively, the same wmpactness may be attained with less reduction of sectional area.

Since the compacting oi the strand is largely a drawing process, there are involved considerable forces acting on the strand; anti-friction bearings of any suitable form may therefore be laid up helically together and drawn through a die, and are further deformed and simultaneously consolidated in a strand.

2. A method of manufacture of compacted wire strand in which circular wires are drawn separately between a tapering mandrel, provided with shaping grooves, and a tapering die, being deformed by the contact with the grooves and die, and the wires are then assembled, laid up helically together and drawn through a die, being further deformed thereby and simultaneously consolidated in a strand.

3. A method of manufacture of compacted wire strand in which circular wires are separately dea formed byradial compression in shaping means, the wires are then laid -helically together in a layer in such a way that circumferential compression is exerted on each wire by its neighbours, and the layer of wires is then compressed to the final shape and dimensions.

4. A method of manufacture of compacted wire strand in which circular wires are separately deformed by radial compression in a converging annular throat formed between a mandrel and a die, the deformed wires are then laid helically together in a layer in such a" way that circumferential compression is exerted on each wire by its neighbours, and the layer'of wires is then compressed to the final shape and dimensions.

5. A method of manufacture of compacted wire strand in which, during stranding, each of a number of circular wires is first deformed by subjecting it separately to radial compression during its passage through a die, the deformed wires are then laid helically together in a layer and-circumferentially compressed by passage through another die, and the layer of wires is then compressed to the final shaperand dimensions.

6. A method of manufacture of non-circular pre-spiralled compacted wire strand in which each of a number'of circular wires is first deformed by subjecting it separately to radial compression, the wires are then laid helically together in a layer and circumferentially compressed, and

the layer of wires is then compressed to the final non-circular shape and dimensions by passage through means which is rotated about the axis of the strand at a speed which bears a pre-determined relation with the speed of longitudinal movement of the strand, the relation being determined bythe required pitch of the 'pre-spiralled strand. I

7. A method of producing compacted wire strand, the interior of which is completely filled the layer of wires is then compressed to the final shape and dimensions, and the core of filling material is thereby radially compressed by the surrounding wires to completely fill the interior of the strand.

8. A compacted wire strand, the interior of which is completely filled with a mouldable, flex-- ideformed in a layer of the same shape as the exterior of the said inner part, they would enclose that part with substantial clearance around it, and deforming the wires of this layer during assembly to bring the size of the layer down to cause it to fit on the said inner part, the deformation of the said wires being substantially complete at the time of first engagement between the adjacent surfaces of the layer and the said inner part.

10. A method of manufacture of compacted .wire strand comprising the steps of assembling, around an inner part of the strand, a layer formed of circular wires, of which the number and diameters are so selected that, if closely assembled while undeformed in a layer of'the same shape as the exterior of the said inner part, they would enclose that part with substantial clearance around it, and deforming the wires of this layer during assembly to bring the size of the layer down to cause it to fit on the said inner part. said deforming being carriedout in two stages, in the first of which the wires are reduced in radial dimensions and increased in circumferential dimensions, and in the second of which they are deforming being carried out in two stages, in the first of which the wires are acted on singly and are reduced in radial dimensions, and in the second of which they are laid together and brought into their final form.

12. A method of manufacture of compacted wire strand comprising the steps of assembling, around an inner part of the strand, a layer formed of' circular wires, of which the number and diameters areso selected that, if closely assembled while undeformed in a layer of the same shape as the exterior.of the said inner part, they would enclose that part with substantial clearance around it, and deforming the wires of this layer during assembly to bring the size of the layer down to cause itto fitonthe said inner part, said deforming being carried out in two stages, in the first of which the wires are compressed radially by being drawn through a converging annular throat between a mandrel and a die and in the second of which the wires are brought together and finally shaped in a die.

13. A method of manufacture of circular compacted wire strand, in which the compacting of the wires is efiected layer by layer so that the deformation of the wires of any one layer is substantially complete'at the time of first engagement between the adjacent surfaces of that layer and an underlying inner part of the strand, and

r in which all the wires of the strand are originally circular wires of the same diameter and the number of wires enclosed by any layer is a squar number.

GAVIN MURE HARRIS. 

